WEB Process-induced material structure phenomena in composite-metal hybrid jointsTuesday (22.09.2020) 10:40 - 10:55 Z: Special Symposia II Part of:
The research of the material structure in hybrid joining zones of metal and thermoplastic fiber composites, caused by the joining process, plays a significant role regarding the improvement of process control as well as to a more efficient load-bearing assessment. On this, one of the focus is on the interaction between reinforcement fibres and molten thermoplastic polymer of the composite material.
In this study, first LS-Dyna results are presented of numerical modelling an one side clamped wire placed in a thermoplastic melt via the interface-based strategy with ICFD-solver and the integrated strategy based on the Arbitrary Lagrange-Eulerian (ALE)-solver. Here, the focus is on the interaction between solid and fluid, as well as on the interaction due to the collision of deformed solids with each other. Both the type of discretization (1D/3D) of the solid and the interactions between several solids in the fluid are addressed. For a numerical evaluation of various solution strategies, the theoretical approach for the analysis of the deformation of flexible structures in a flow according to  is applied. An additional test stand for validation is set up and is applied using a plate-plate rheometer, whereby individual fibers or fiber bundles are sheared in a thermoplastic melt under process conditions. Preliminary tests with fiber bundles under varying shearing angle at constant angular velocity to investigate the system sensitivities are the basis for further design of experiments. Furthermore, the concept of a fiber deformation test rig is explained. The results allow the validation of numerical forming processes in which the displacement of the matrix causes movement of the fiber. The deformation of the fibres, which is gained by CT-scans, but also the force profile for the forming process, shall be used as a parameter. The applied and validated simulation methodology is further utilized for fiber deposition processes and to model the deformation behaviour in a 3D printing process. Hence, it enables the generation of a general valid deformation simulation and contributes to versatility and flexibility.
 Luhar, M.; Nepf, H. M.: Flow-induced reconfiguration of buoyant and flexible aquatic vegetation; Limnology and Oceanography, Vol. 56; No. 6; P.2003-2017, 2011, DOI: 10.4319/lo.2011.56.6.2003